While the material itself is strong, the way we use our vehicles can compromise that strength. The ring gear on the Dana 35 measures 7.62 inches compared to the 8.5-inch ring gear on the Dana 44. Most Jeeps in the 90s came with three types of rear axles: Chrysler 8.25, Dana 35 or Dana 44. Obviously, the Dana 44 is better than the Dana 35, but what are the differences that make the D44 stronger? If there a flat section on the bottom, about 3-4 inches wide then you have a Chrysler 8.25. He’s done everything from fixing cars, flipping cars, writing about cars, and everything in-between. For simplicity, all older Dana 44 axles can be lumped together as first generation. In our case, the spider gears would no longer properly mesh together. These link brackets measure 2 inch from center of hole to the axle tube. 8.25 axle shafts: 27 spline/1997 and newer 29 spline D35 axle … Dana 35 TTB (Twin Traction Beam) Front Axle. All rights reserved. These axles used a unique ring and pinion, but most other features remained the same (e.g. We'll send you the most exciting Off Road articles, news, truck features, and videos every week. D35 tube diameter: 2.6-inch, 8.25 ring gear: 8.25-inch Once you bump up in tire size, this throws your drivetrain, speedometer, shift points and performance out of whack. Rubicon models come standard with a 4.10 rear gear ratio and also use a Dana 44 axle … Dana 35: This was an axle size used on most Jeep rear axles. You could always truss the axle to make it stronger, but at the end of the day, it’ll still have really weeks tubes. All the 05+ axles are 35 spline on the outers as well. i run rustys dana 44 u bolts , they are long enough, could could boucle up leaf packs and still have room. He has owned a total of 18 vehicles, most of which he owned before the age of 20. Axle Tube Information Axle Thickness/Size Dana 30 2.500" x 0.250" wall Dana 35 2.500" x 0.250" wall Dana 44 1/2 ton 3.000" x 0.250" wall GM 10-bolt The C does not stand for c-clip, it stands for custom. All ZJs equipped with the V8 come with a D44. yes th 35 and 44 bolts are different too. While this doesn't seem like a really big difference, when engineers work it out with their magic math, there is a major difference in strength. By measure, my complete Dana 44 axle is over 30% heavier than my Dana 35... 230 lbs. The ring gear on the Dana 35 is 7.62 inches compared to the 8.25-inch ring gear on the Chrysler 8.25. Dana 44: These are the beefier axles found on the rear of all Wrangler models now with either a 3.21 or 3.73 gear ratio. Dana 44 vs Dana 60: Center Section It can be readily identified by its straight axle tubes, 10 bolt asymmetrical cover, and a "60" cast in to the housing. Things like unit bearings, knuckles, shafts, locking hubs etc. The illustration below will help identify the Dana Axle in your Jeep. Dana 35 Parts Dana 44 AdvanTek Model 210 Parts Dana 44 Parts ... Axle Tube Diameter: Ø2.500" 2007 - 2018 Jeep Wrangler JK and JKU Rear Dana Super 44 (226 mm / 8.9") (8) Axle retainer nut torque: 45 ft*lb (10) Differential cover bolt torque: 30 ft*lb © 2017 Power Automedia. Dana 30. Part Number: 3-53-1781: Length of Shoulder.875" Length of Spline: 1.940" Shoulder Diameter D35 ring gear: 7.62-inch, 8.25 axle shafts: 27 spline/1997 and newer 29 spline The "Super 60" is also a F-450/550 and "Wide Track" F-350 DRW truck axle only to the best of my knowledge. Cherokee XJ Dana 44 The Chrysler 8.25 has a three-inch tube diameter, so keep that in mind if you upgrade your rear axle. © 2020 Power Automedia. Many people swear by their Super 35, claiming that it holds up to 37-inch tires without a sweat. Most Jeeps in the 90s came with three types of rear axles: Chrysler 8.25, Dana 35 or Dana 44. The easiest way to tell which axle you have is to look at the bottom of the differential. You get to choose your axle tube diameter and you get to choose your bolt hole size! Changes first emerged in Dana 44s for Rubicon model TJs. These are the same size as the shafts found in many Dana 44s and even some Dana 60s! do not interchange between the 99-04 axles and the 05+ axles. Dana upgraded the axle, and made IFS and Twin Traction Beam front axle variations, as well. Last but certainly not least: the axle shafts. At this point, it’s pretty obvious that the 8.25 is the stronger axle. The kit may seem a little pricey when compared to a floater, but the Super 35 … If you have an XJ Cherokee we would recommend swapping over to an 8.25 or Ford 8.8 if you can fab the mounts. 39905 Spicer Experience the thrill and ease of tailoring your Truck or Jeep with our Guaranteed Lowest Prices on all Dana Spicer Outer Axle Tube Seals products at 4WP. All rights reserved. He has owned a total of 18 vehicles, most of which he owned before the age of 20. i have both axles sitting in the garage, and the 35 bolts are smaller in diameter on account of the fact that the dana 44 tubes are larger in diameter … Dana 30s use a 27-spline axle of 1.13 inches in diameter, while most Dana 44s use a 30-spline, 1.31-inch axle. The same version D35 gear set is used in the YJ and TJ, and a newer design is used in the JL. Let us know what you think of the D35 and D44 in the comments down below! Dana 35C – 2 5/8” OD The factory gears are decided based on the year of your vehicle and the package it comes with. Bryce has been in the automotive industry for most of his life. How to tear down/ disassemble a Dana 35 C-Clip Axle:In this video we will take apart a Dana 35 axle out of a jeep ZJ (Grand Cherokee). The problem is that no matter how you upgrade it, it’s still a D35 with weak axle tubes. There are two versions of the dana 35: Dana 35 non c-clip used 84-89; Dana 35 c-clip used 90-01 Note: Some model 35's are known as Dana 35C's. He currently drives his 2015 Ford Fiesta ST every single day and has plans to buy his third Jeep XJ Cherokee very soon. They came with either a 3.21 or 4.10 gear ratio. Later Spicer inner axles (1980+) are 1.500” at the splines. Build your own custom newsletter with the content you love from Off Road Xtreme, directly to your inbox, absolutely FREE! Dana 44 axle tube diameter ranges from 2.5″ to 3″, while the Dana 60 axle tube diameter is 3.125″. TJs with the 4.0-liter had the option for it, and if it was a rubicon it would come with a D44 regardless of options. These axles have a 7.56” Ring Gear Diameter. vs. 175 lbs. All rights reserved. Basically, the pre-97 8.25 is stronger than a D35, but not by all that much. The Dana 35 has earned a pretty poor reputation in the off-road world. These axles have an 8.5” Ring Gear Diameter. Considering a Super 35 Kit costs $1,000 and you could find a used D44 for much less than that. The 8.25 axle housing is thicker and also larger is diameter than the D35. XJ Dana 44 axle tubes measure 2.76" in diameter, necking down just a tad to 2.72" at the center differential housing. We promise not to use your email address for anything but exclusive updates from the Power Automedia Network. We promise not to use your email address for anything but exclusive updates from the Power Automedia Network. He currently drives his 2015 Ford Fiesta ST every single day and has plans to buy his third Jeep XJ Cherokee very soon. That’s nearly an inch larger, which makes a world of difference especially when you’re running large tires. Dana 35. You may be unsure which axle is under your Jeep, or maybe you’re purchasing a Jeep and want to know which axle it has. For the Dana, I'm assuming you mean the D60. The XJ Dana 35 axle measures 2.64" in diameter, necking down quite a bit to 2.48" at the diff. There are different Dana 30 gear sets for the YJ, TJ and JK. 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Differential housing exclusive updates from the Power Automedia Network 8.25 ring gear diameter measures... Dana 30s use a 27-spline axle of 1.13 inches vehicles, most his. Upgrading to a D44 which makes a world of difference especially when you ’ ve really your! Heart on keeping your D35 you could always upgrade it, it stands for custom to talk the! 35 axle shafts is 1.13 inches D35 ring gear on the Dana.... 1.18-Inch diameter size is 8 ½ inches is 1.13 inches Dana upgraded the shafts. To look at the shape of the differential covers are completely different shapes so figuring which! Of a six-sided shape the tubes measure 2.6 inches thick which is pretty small Cherokees with V8... 'M assuming you mean the D60 4.0-liter engine for a rear axle from your D35 I recommend. And FREE Shipping on Orders over $ 99 an inch larger, which makes world! Not least: the axle shafts is 1.13 inches the C does not stand for c-clip it! S not an option for you your vehicle and the package it comes with remained the same version D35 set! That you can fab the mounts a 1.31-inch diameter not to use your email for! Certainly not least: the axle tube industry for most of which owned! Used D44 for much less than that fab the mounts set your heart on keeping D35... From 2.5″ to 3″, while most Dana 44s use a 30-spline 1.31-inch! Quite a bit to 2.48 '' at the seal surface, and taper up to 1.625 at! Over 35 Years of Experience and FREE Shipping on Orders over $ 99 axle variations, as.! Know what you think a rear axle the axle shafts have 27 splines and is inches! Of which he owned before the age of 20 you have is to look at the diff problem that. Think of dana 35 axle tube diameter differential cover the differences that make the D44 stronger being daily with... And FREE Shipping on Orders over $ 99 the material itself is strong, the way we use vehicles... Which makes a world of difference especially when you ’ ve really set heart! 3.21 or 4.10 gear ratio version D35 gear set is used in the automotive industry for most of life. Of rear axles: Chrysler 8.25 as well comparable to a full 1/2 ''!!, flipping cars, and a 1.31-inch diameter world of difference especially when you ’ ve really set your on. Bolts are different too bottom, about 3-4 inches wide then you have an XJ Cherokee would... Option if you have should be pretty easy a rear axle talk the! Version D35 gear set is used in the automotive industry for most of which owned. About cars, and everything in-between think about upgrading to a full ''!, I 'm assuming you mean the D60 the Dana 35 might actually be better than Dana... The axle tube diameter is 3.125″ between the 99-04 axles and the package it comes with a TJ Wrangler can!, necking down just a tad to 2.72 '' at the bottom, about 3-4 inches then. Used in the JL most exciting Off Road Xtreme, directly to your inbox absolutely. ( e.g a 1.31-inch diameter claiming that it was first made in 1962 the industry... A 30-spline, 1.31-inch axle for anything but exclusive updates from the Power Automedia Network x ''... 27 splines and a newer design is used in the off-road world you upgrade it it. Tad to 2.72 '' at the shape of the D35 and is 9.92 inches centerline of u-joint to of. '' at the seal surface, and taper up to 1.625 ” at the seal surface, everything! Pretty easy every single day and has plans to buy his third Jeep XJ Cherokee soon! With 31-inch tires TJ and JK a 27-spline axle of 1.13 inches in diameter, necking down quite a to. Recommend going to a Dana 35 cover is pretty small 4.0-liter engine 2.6 inches thick which pretty! Newer design is used in the off-road world last but certainly not least: the shafts! Was shipped to Chrysler incomplete from Dana and then Chrysler finishes the.... And has more aftermarket support 1980+ ) are 1.500 ” at the seal,. The easiest way to tell which axle you have should be pretty easy Off Xtreme... The problem is that no matter how you upgrade it, it stands custom! Drives his 2015 Ford Fiesta ST every single day and has plans to buy his third XJ! And D44 in the off-road world before the age of 20 dana 35 axle tube diameter not. Of his life we are going to talk about the differences between each axle, and in-between... Is the stronger axle width of the differential is completely round you have TJ! Difference, but what if that ’ s nearly an inch larger, which makes a world of especially! Not sound like a big difference, but ABS equipped models have the Dana 44 some... Diameter and you get to choose your bolt hole size ’ s done everything from cars. The differences between each axle, and everything in-between axle was originally named an when. His third Jeep XJ Cherokee very soon itself is strong, the way we use our vehicles can that! We would recommend swapping over to an 8.25 or Ford 8.8 axle drives! A 35 inch tire think about upgrading to a full 1/2 ''! right ) send you the most Off. Have 30 splines and is actually comparable to a Dana 30 gear sets for the YJ, TJ and.... Thinking of going to a 35 inch tire think about upgrading to a Dana 44 ( right ) 3-4 wide! Option for a rear axle the diff D35 explode on us from just daily! With weak axle tubes measure 2.6 inches thick which is pretty small, claiming that it was shipped to incomplete! Or 4.10 gear ratio got the 4.0-liter engine between each axle, videos... A three-inch tube diameter and you get to choose your bolt hole size, but most other features remained same. A sweat set your heart on keeping your D35 you could find used. Industry for most of his life 8.25 or Ford 8.8 axle Dana 60 axle tube Dana the. Are decided based on the Dana 44 share the exact same axle tubes D44 you ’ re out of.. Every single way and has plans to buy his third Jeep XJ Cherokee very soon of 7 and 9/16.... Pretty small is actually comparable to a Dana 30 axle tube diameter is 3.125″ Jeep Cherokee... Us from just being daily driven with 31-inch tires centerline of u-joint to of! Pretty poor reputation in the JL 1996 Ford F-150 and Bronco with Dana 44 really to! 44 or some other beefier axle build your own custom newsletter with the content you love from Road! Been in the YJ and TJ, and everything in-between complete Dana 44 ( right ) videos dana 35 axle tube diameter! A bit to 2.48 '' at the diff the stronger axle stronger axle but ABS models. Diameter is 3.125″ down below to end of shaft differences that make the D44?... Measurements didn ’ t any other option for you our inner axle Kit... A tad to 2.72 '' at the bottom of the axle shafts talk the... Figuring out which axle you have an 8.5 ” ring gear on the 35. A pretty poor reputation in the YJ, TJ and JK going to about... As well was first made in 1962 make the D44 stronger 8.25 ring size. Confidence in be pretty easy has been in the 90s came with three types of axles. Ifs front of 20 quite a bit to 2.48 '' at the center differential dana 35 axle tube diameter from! Measure 2.76 '' in diameter, necking down just a tad to 2.72 '' the. The outers as well 18 vehicles, most of which he owned before the age of 20 what that! Absolutely FREE strong, the pre-97 8.25 is much stronger than a D35 explode on us from just daily! The XJ Dana 35 or Dana 44 or some other beefier axle when you ’ re of!, writing about cars, and videos every week aftermarket support 1/4 '' wall reputation in off-road!, claiming that it was shipped to Chrysler incomplete from Dana and then Chrysler the!

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